2013 xc60 knocking sound
 

Hi, everyone
Apologies if this post appears in the incorrect location this is my first attempt. Where to start? So I have recently found a knocking noise coming from my drivers side whilst accelerating hard out of left hand turns, usually trying to exploit gaps in traffic.
I initially took the car to volvo who diagnosed a cv joint, the whole driveshaft was replaced including both cv joints. To my amazement the fault resurfaced after a few weeks. I don’t tend to drive like I stole it so only noticed the noise when I give it the beans whilst turning left.
I decided to take the car back to volvo who replaced the driveshaft again under warranty, and shock horror the fault is still there! So this is where my problems begin I’ve had the car on a spider ramp and inspected all bushes/joints, rod ends, shocks/coils and mountings..... absolutely nothing to report.
I am totally stumped the noise is not apparent under normal driving conditions no knocking or clicking going round roundabouts or over speed bumps/pot holes, only whilst giving it some going left at junctions.
Don’t get me wrong I know the answer is don’t give it stacks whilst driving but I really want to know what’s causing this. My only other thoughts could be a engine mount or loose brake pads but everything seems okay.
If anyone has any ideas please feel free to add you advice I would really appreciate it.

Would also like to add the the vehicle has been inspected by myself, Volvo and my local trusted garage but we are all clueless 😭

I would change the Other driveshaft too . There was a problem with a batch around that time ...

Thanks for your reply, I thought the same also, I have had the other drive shaft out and inspected it on a bench, the bearing is free moving with no signs of friction and all the splines are in very good condition.

TOO freely moving i guess , Try putting the inner splines in a vice with soft jaws and try twisting the outer joint back and forth at varying angles , i would think you will see play .

if you drive around in a circle at about 10 mph 3/4 steering lock,light pressure on the brake and accelerator applied slightly to get some load on it , it will probably rattle . Try Left and right circles . someone standing outside will hear which side the rattle is from .

Update
 

So I have now had the other driveshaft out again with nothing to report, no damage or play. The sound I hear is more like a thud than a cv joint knocking. Car has been inspected again by an independent volvo specialist and still no fault has been found, might be worth a mention but it is hard to recreate the fault when someone is sat in the passenger seat. Am I just going to have to wait for this to get worse before it’s found? Feel like banging my head on a wall. Is it time to just start replacing and hope for the best?

is it a fast rattle/knock when going around in a circle with 75% lock applied and throttle load affects it ?

Yes speed related however over 20mph it dies off only affected by harsh acceleration, but is not constant whilst driving in a circle. It only happens under initial engine torque, this is why I’m confused. With extreme concentration it sounds like it is centre engine area but so hard to tell when your driving. Standing outside the car it is hard to pin point area of noise, closest I have come is my mechanic saying ‘front Of the car’

Difficult , but this was a problem with a very few the older XC60 , and was the driveshaft, one side or the other or both . the person standing outside should be able to tell which side it is from as should you in the car , but no two cases sound the same i guess!

I think I’m just guna have to try a new drive shaft and hope for the best will update with results thank you for your help